Design of Turnouts

Standard Lengths of Tongue Rails:

Gauge Number of crossing Length of tongue rail

B.G 1 in 8.5 4.72 m

B.G 1 in 12 6.40 m

B.G 1 in 16 9.76 m

M.G 1 in 8.5 3.96 m

M.G 1 in 12 5.49 m
Use of various crossings on Indian Railways
i. 1 in 6 crossing. This is generally used in symmetrical splits.
ii. 1 in 8.5 crossing. This is used in station yards where space is
restricted and speed is low, i.e., on sharp turnouts.
iii. 1 in 12 crossing. This is used in the station yards of main lines, i.e.,
on flat turnouts.
iv. 1 in 16 crossing. This is used at very high speed turnouts on B.G
and M.G routes only.
DESIGN OF TURNOUTS
• A turnout, after branching off from the main track, may run into various directions of which running parallel to the original track is most
common. The design calculation of various turnouts is based on following three factors:
(1) Method of calculating various leads
(2) Method employed for crossing angle
(3) Type of tongue rail used
Notation used in design calculation
Following notation have been used in various methods for design of turnouts:
CL = Curve lead
= Distance between theoretical nose of the crossing (T.N.C.) and the tangent point ’T’ measured along the length of
main track.
SL = Switch lead
= Distance between tangent point ’T’ and the heel of the switch (H.S.) measured along the length of the track
L = Lead or crossing lead
= Distance between T.N.C. and the heel of the switch (H.S.) measured along the length of the track

• Lead rails, being curved rails, are not measured along their curve length, long their projected length along the straight rail.
Therefore, CL, SL and L, it is clear that
CL = SL + L
or L = CL - SL
• β = Angle of the switch, i.e. the angle between the
gauge faces of switch rail and stock rail
• α = Angle of the crossing
• d = Heel divergence or clearance
• Ro = Radius of the outer turnout
• R = Radius of centre line of the turnout
• G = Gauge of the track
• N = Number of the crossing
• D = Distance between T.N.C. and tangent point of
crossing curve
• Different method of the turnout design Three methods is used for design of
turnouts
Method I: The important steps of this method are
(a) All three leads, CL, SL, and L are calculated. The CL and SL are particularly
calculated in this method.
(b) Crossing angle (α) calculated using right angle method
(c) Crossing curve is considered to start from an imaginary tangent point ahead
of actual toe of the switch and end at T.N.C.
This arrangement results formation of three kinks,
a) Kinks at the toe of the switch. Due to straight tongue rail.
b) Kink at heel of the switch. Due to non-tangential of tongue rail to the curve.
c) Kinks at toe of the crossing. Because the curve is carried theoretically up-to
T.N.C. but crossing actually is straight.

• This design method all three kinds of kinks and was common in the past. But
now a days used in unimportant lines and sidings.
• Design calculation of method I:
Value of gauge (G), Heel divergence (d) and Angle of the crossing (α) are
given
Curve lead (CL) CL= 2GN
𝐺
R-Radius Hence R = Ro –
2
Ro = 1.5G + 2GN²
SL = 2𝑅𝑜. 𝑑
Lead or crossing lead (L) L = CL – SL
= 2GN - 2𝑅𝑜. 𝑑
Heel Divergence (d)
From equation
SL = 2𝑅𝑜. 𝑑
(SL)²
d=
2𝑅𝑜
 Ex. 1:- Calculate all the necessary elements required to set out a 1 in 8.5 turnout, taking off from a straight BG
track with its curve starting from the toe of the switch i.e. tangential to the gauge face of the outer main rail & passes
through TNC. (Heel divergence, d = 11.4cm)
Solution:- Given, N = 8.5, G = 1.676m, d = 11.4cm = 0.114m
1) Curve Lead, CL = 2GN
= 2 x 1.676 x 8.5
= 28.49m
𝐺
2) Radius, R = Ro – 2
Ro= 2 GN ² +1.5G
= 2 X 1.676 x 8.5 ² + 1.5 X 1.676
= 242.18 + 2.51
= 244.69m

1.676
➢ R = 244.69 –
2
= 243.85m
3) Switch Lead, SL = 2𝑅𝑜. 𝑑
= 2 𝑋 244.69 𝑋 0.114
= 55.8
=7.45m
4) Lead, L = CL – SL
= 28.49 – 7.45
= 21.04m
Conversion of N into α and vice-versa by right
angle method, the values are given below:
Number of crossings i.e., N Angle of crossing i.e., α

1 in 8.5 6° 42’ 35”

1 in 12 4° 45’ 49”

1 in 16 3° 34’ 35”
Ex. 2:- Calculate all the necessary elements required to set out a 1 in 12
turnout, taking off from a straight B.G track with its curve starting from 𝐶𝐿
the toe of the switch i.e. tangential to the gauge face of the outer main 2) Ro =
rail & passes through TNC. (Heel divergence, d = 11.4cm) sin α
40.26
Solution:- Given, N = 12, G = 1.676m, d = 11.4cm = 0.114m =
sin 4° 45’ 49”
From right angle method, 40.26
=
cot α= N = 12 0.0828
= 485.69 m
α =cot−1 12
𝐺
α =4° 45’ 49” ❖ R = Ro –
2
1.676
So, now given data becomes R = 485.69 –
2
α =4° 45’ 49” = 484.852 m
G = 1.676 m
d = 11.4 cm = 0.114 m 3) Switch Lead, SL = 2𝑅𝑜. 𝑑
= 2 𝑋 485.69 𝑋 0.114
α
1) Curve Lead, CL = G cot = 111
2
4° 45’ 49” = 10.5 m
= 1.676 X cot
2

4) Lead, L = CL – SL
= 1.676 x 24.0.5
= 40.26 – 10.50
= 40.26 m
= 29.76 m
• Method II The important features of this method are:
(i) Only the cross lead ‘L’ is calculated
(ii) The curve is tangential to the tongue rail. It springs up from heel of
switch and ends at T.N.C.
(iii) Out of three kinks, kinks formed at heel of the switch is removed

This method was common in UK in past

• Design Calculation With given value of gauge (G), d, β (angle of switch)
and α, the turnout is designed:

tan (α + β)
• Lead or crossing lead (L): L = G – d
2
(α + β)
L = (G – d) cot
2

tan (α + β)
• R-Radius: Ro = (G – d) 2
2 sin (α + β)/2 sin (α - β)/2
(G – d)
➢Ro = and
( cos β – cosα)

𝐺
➢R = Ro –
2
Ex. 3:- Calculate elements of a turnout, when it is given G = 1.676 m, N = 12, d = 13.3 cm & angle of
switch, β = 1° 8’ 0”.
Solution:
Here, N = 12, α = 4° 45’ 49”
(α + β)
1) Crossing Lead, L = (G – d) 𝑋 cot
2
(4° 45’ 49” +1° 8’ 0”)
= (1.676 – 0.133) X cot
2
(5°53′ 49")
= = (1.676 – 0.133) X cot
2
= 1.543 X 19.4143
= 29.950 m
(G – d)
2) Radius, Ro =
( cos β – cosα)
(1.676 – 0.133)
=
( cos 1° 8’ 0” – cos 4° 45’ 49” )
= 475 m
𝐺
❖ R = = Ro –
2
1.676
= 475 –
2
= 474.162 m
• Method III The important features of this method are:
(i) This method is very similar to method II. But here the straight length at
crossing is provided.
(ii) So one end of the curve is tangential to tongue rail and spring up from
the toe of the crossing and is tangential to the straight length of the
crossing.
(iii) In this method kinks at toe of the switch and kinks at heel of the
switch are removed.
(iv) It is suitable where tongue rails and crossing are straight. This method
permits the use of built-up tongue rails and crossings of heavy rail
sections.
• Design Calculation Let the straight length of the arms at crossing be x = T’C

• R-Radius: With given G, D, α, β and x

(G – d – x sin α)
➢Ro =
( cos β – cosα)

𝐺
➢R = Ro –
2
• Crossing Lead (L)
L = CN + NS = ON + T’P = x cos α + TP cot (𝛼+ 𝛽2)
L = x cos α + G’ cot (𝛼+ 𝛽2)
= x cos α + (G – d – x sin α) cot (𝛼+ 𝛽2)

• d = x sin α - G – ((L– x cos α) / cot (𝛼+ 𝛽2))

• To get value of method II put x =0
Summary:
• Points and crossings are provided in the railway track to provide
diverging arrangement for the train, from one track to another. They
also required in yards and for shunting works. They control the
movement automatically in the desired direction and the driver is not
required to do anything.
• The points and crossings are weak points in the track and vehicles are
susceptible to derailment at these locations. It is, therefore necessary
that a turnout should be properly designed by the recommended
method and special care should be taken to see that they are
correctly laid.